Soft glass and composite article



R. H. DALToN 2,643,020

SOFT GLASS ANO COMPOSITE ARTICLE 2 Sheets-Sheet l lnbsntnt /faafkr fu ra/v Stturneps June 23, 1953 vFiled Maron 4,' 194e June 23, 1953 R. H. DALTON 2,643,020

SOFT GLASS AND COMPOSITE ARTGLE Filed March 4, 1946 2 Sheets-Sheet 2 5/ i i 4, zlisllalsl s@ l l l e sv l s IO 'o I .1l

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nhentur my /fwrw Qtturneps Patented June 23, 1953 SOFT GLAss AND COMPOSITE ARTICLE Robert H. Dalton, Corning, .N. Y., assigner to Corning Glass Works, Corning, N. Y., a corporation of New York Application Maren 4, 194s, serial No. 651,818 1 Claim'. (C1. 22o- 2.1)

This invention relates Vto the fabrication of glass articles by welding, preformed glass parts together and particularly to compositions having special properties which make them suitable as brazing or soldering media for such purposes. The joining together of glass parts by inter-fusion thereof requires a practically perfect match in expansion coefcients of the glass parts to be joined and a careful control of local temperatures in and near the joint. A high degree of manual skill or complex machinery is also essential despite which distortion of the glass parts adjacent to the joint invariably occurs.

The primary object of this invention is to provide a fusion weld between glass parts at lower temperature than has heretofore been possible and Without distorting the parts at or adjacent to the weld.

Another object is to provide glass compositions for forming such weld's.

Another object is to provide glasses having unusually low softening temperatures together with expansion coefcients suitable for uniting sodalime-silica glasses and other glasses of similar expansion characteristics.

Another object is to provide a method for sealing together glass parts of considerable size or complicated shapes whereby the glass parts are uniformly heated throughout and are not subjected to thermal shock.

Another object is to provide a method for sealing together glass parts which does not require a high degree of manual skill nor the use of complicated sealing machinery.

A further object is to provide fabricated glass articles comprising preformed glass parts joined by a fusion weldV of another glass having a lower softening temperature than the glass parts.

Another object is to seal a glass partition within a hollow glass body, such as a glass cell or.

tube.

The softening temperature of a glass as referred to herein is that temperature at which a thread of the glass, .65 to 1 mm.I in diameter and 23 cm. long, will elongate at the rate of 1 mm. per minute when heated throughout the upper 9 om. of its length. See A method for measuring the softening temperature of glasses, by J. T. Littleton, Journal of the American Ceramic Society, vol. 10, page l259 (1927).

In Order to form a fusion weld between two glass parts without distortion thereof, a small amount of another glass may be employed as a brazing or soldering glass which has such a'low softening temperature that it will melt and flow at temperatures considerably 4loelovv the softening temperature of the glass parts. I have found that forbest results the softening temperature perature at which all strain in the glass is released in about fifteen (l5) .minutes See A method for determining the annealing temperature of glass, by Littleton and Roberts, Journal of the American Optical Society, vol. 4, page 224 (1920).

The soft brazing glass will, of course, differ in composition from the glass parts to be joined. Ingredients which are most effective in lowering the softening temperature of glass comprise the alkali metal oxides, boric Oxide, lead oxide, etc.

The amount of the alkali metal Oxides which may be employed for this puropse is limited by the desired expansion coefficient of the glass because the alkali metal oxides increase the expansion coeflcient more than any other material. Lead oxide also causes a substantial increase in the expansion coefficient. All such ingredients, when used in very substantial amounts tend to lower the chemical durability of the glass or its resistance to attack by water and chemical reagents. Materials, such as alumina, which increase the chemical durability of glass generally have a hardening effect and tend to raise its expansion coefficient as well as its softening temperature.

I have found that in glasses which consist essentially of PbO, B203 and Si02, and in which the PbO exceeds the substitution of A1203 for S102 unexpectedly lowers the expansion coecient of the glass (and in some cases also its softening temperature) and at the same time improves its chemical durability and resistance to devitrifcation. This is unusual, because it is well known that Si02 is very effective in lowering the expansion 'coefficient of glass and removal of Si02 ordinarily raises the expansion coefcient.

I'have further found that the lowering of the expansion coefcient, which is thus brought about by the substitution of A1203 for Si02, may be compensated by the addition of more PbO. Since Pb0 tends to soften the glass while raising its expansion coefficient, the net result is that replacement of Si02 by A1203 and PbOpermits softening the glass without substantially changing its expansion coefficient.

By such means I have been able to produce glasses which have expansion coefficients between x 10-'1 and 90 x 10*7 per. C. (0 to 300 C.) and which have softening temperatures below 500 C. and as low as 430 C. These new soft glasses are particularly suitable for forming seals between glass parts composed of commercial compositions such as the soda-lime glasses and others of similar expansion characteristics. The softening temperature of commercial soda-lime glass, such as window glass, is in the neighborhood of '700 C. or higher, and the annealing temperatures are above 500 C. The expansion coefcients to 300 C.) of such glasses range from about 80 x 10I to 100 x 10-Fl per DC., this range being particularly suitable for forming seals using the new soft glasses, as will later appear. The new glasses have chemical durability and resistance to devitriflcation adequate for the purposes hereinbefore set forth.

The new glasses on the oxide basis Vcomprise at least three components consisting of PbO, A1203, and one or both of the glass-forming oxides B203 and S102. The term glass-forming oxides, as used herein, refers to those oxides which have the property of forming glasses of and by themselves when cooled from a molten condition. According to the book Properties of Glass, by G. W. Morey, the outstanding glass-forming oxides are B203, Si02 and P205, but P205` is not suitable in the present glasses. l

The new glasses may contain 60% to 85% PbO', 5% to 15% A1202, 0% to 40% B203, and 0% to Si02. Preferably, the proportions should be '70% to 80% PbO, 5% to 15% A1203, 5% to 20% B203, and 0% to 10% S02, because the latter proportions produce glasses which have softening temperatures less than 500 C. and expansion coefficients between '75 l0 and 90 107 per C., and which are particularly suitable for joining commercial soda-lime and other glasses of similar expansion characteristics.

Preferablythe new glasses consist of the four components Pb0, A1203, B203, and Si02 in the proportions stated above, but minor amounts of other constituents may also be present subject to the following considerations. The amount of such minor constituents preferably should not exceed about 2% to 5% but in some instances may amount to as much as 8%' or 10% of the total glass composition. The alkali metal oxides, if present, should not exceed about 1%, because they cause a decided increase in the expansion coefficient of the glass without advantageous gain in softness. Other minor constituents may include oxides of the metals of the second periodic group and bismuth oxide. Fluorine aids somewhat in lowering the softening temperature of the glass but also tends to cause devitrication and to lower its chemical durability if very much of it is present. It may be introduced 'as lead fluoride, aluminum fluoride or alkali metal fluoride. The following compositions which are expressed in terms of weight percentage as calculated from their batches generally illustrate glasses which are within the scope of the invention softening Temp., "C Expansion coefficient per 0 .Xl0"..

Composition 1 is particularly suitable for my purpose. In Composition 2 part of the lead is introduced as PbF2, but on the oxide basis the total percentage of lead in this glass is about '71% PbO. In the new glasses the percentage of PbO should not be more than about 1'7 times the percentage of A1203 and it will be noted that in the above examples it does not exceed seven times the A1202. The high alumina content with respect to PbO is a distinguishing characteristic of the present glasses and is higher than was heretofore believed desirable for soft glasses and glazes of high lead content. As pointed out above, the presence of a relatively high alumina content in the present glasses is largely responsible for their unusually low softening temperatures and other desirable properties.

The above described soft glasses may be applied to the junction of preformed glass parts complished while the glass part is still hot from holding or pressing. The hot surface to be coated may alternatively be dipped into the soft glass, the latter being either molten or pulverized. In the latter case the powdered soft glass becomes sticky and adherent from the heat of the glass part. Thin rods, strips, or washers of the soft glass may be inserted between the parts to be joined and subsequently heated in place or a rod of the soft glass may be rubbed or smeared on to the hot surface to be joined. Other methods of applying the soft glass to the joints of the glass parts may include applying it either as a molten liquid or as a slurry comprising a powder in a vehicle such as cellulose nitrate solution, by flowing, brushing, or spraying, or by means of a coating roller. The powdered soft glass may be attached in appropriate patterns to paper or other suitable backing material by means of anv adhesive and thereafter may be applied to the surface to be coated. washers composed of the soft glass or of a sin'tered powder thereof may be employed. The part to be coated may also first be coated with an adhesive and dipped into the powdered soft glass to obtain a coating thereof.

The glass parts to be joined, having thus been coated with the soft glass, are brought together and heated suiciently'to cause the soft glass to flow and fill the joint, but insufficiently to soften the glass parts themselves. Heating is preferably accomplished by passing the article throughv a lehr or oven, whereby the composite article when finished is also annealed. However, it may also be accomplished through the application of local heat sufficient for the purpose by the use of a flame, or by electric inductive heating, or, in the case of thin articles, by the application thereto of a hot metallic body in the neighborhood of the seal.

The amount of the soft glass which is required to fill the joint is relatively small and will depend upon the character of the surfacesA to be joined. With surfaces which are formed so as to lit closely and accurately a very thin layer of the soft glass suffices to make a satisfactory seal.

glass is required, the amount in any case being sufficient to fill all irregularities of the junction.

When the parts fit closely and the layer of the soft glass is very thin, the average values of the vex- Preformed gaskets orV With less closely tting joints, a larger amount of the softA pension ceffiintof the soft glass'ibetween room' within about 20 or 30 l0l per PC. of thatl of the glass parts.. The` setting point temperature' is thetemperature below which theglass has insufficient plastic'flow to relieve strains set up in the'glass during cooling. For most glasses vthis temperature is approximately 10 to 20 C. below their annealing temperatures. I have found that the expansion coefficient (cv to 300 C.) of the-soft glass should preferably be about 2 to 15 .10'I C. below that of theglass parts to be'joined. rIr'his is because a strain-free seal between two glasses of different' softening temperatures requires that the overall thermal elongation perv unit length between room temperature and the setting point temperature of the softer glass should be the same for both glasses. Under these conditions, the expansion coeilcients (0-to 300 C.) 'of the new soft glasses are about 2 to 15x10 per-C. less than that of commercial soda-lime silica glass and other glasses of similar expansion characteristics. In general, the soda-lime silica glasses which can be joined by means of the new soft glasses comprise the' approximate range of compositions including 70%-76% SiOz, 13 %-18 alkali metal oxides (R20) 8-14% CaO-l-MgO and 1%-3% A1203; Other glasses of similar' expansion characteristics such as lead glasses, barium crown glasses, etc., may also be used.

For a better understanding of the use and application of the new soft glasses to preformed parts of soda-'lime glasses for welding them together and of various glass articles made thereby, reference is had to the accompanying drawings in'which:

Fig. 1 is an elevation partly in :section of an apparatus for producing glass articles provided with a sealing stripn of soft glass'in accordance with theinvention.

. Fig.` 2 is an elevation partly in section of a lamp `comprising twoglass parts joined A by a fusion weldof soft glass in accordance with the invention..

.Fs., 3 is an. .elevation partly in` section .oiga cathode ray tube embodying the invention;

Fig. 4 is a plan view of a double window pane made in accordance with the invention.

Fig. 5 is a fragmentary section on an enlarged scale on the line 5-5 of Fig. 4.

Fig. 6 is a fragmentary section on an enlarged scale of a double window pane during welding in accordance with the invention.

Fig. 7 is a sectional view of a hollow glass building block welded in accordance with the invention.

Fig. 8 is a sectional view of a sheet of foam glass faced with a transparent glass sheet welded thereto in accordance with the invention;

Fig. 9 is a plan view partly broken away of a hollow glass panel for a fluorescent lamp in accordance with the invention.

Fig. 10 is a sectional view on the line III-I0 of Fig. 9.

Fig. 11 is a sectional view of a glass panel similar to that shown in Fig. 9 before -welding the parts together according to the invention.

Fig. 12 is a transverse sectional view of a double bore glass tube during fabrication in accordance with the invention; and

Fig. 13 is a transverse sectional view of a fin` ished double bore tube similar to that shown in' Fig. 12.

Fig. 1 illustrates one method of applying the soft welding glass to the edge of a glass part to be welded to another glass part, for example, the

glass parts of anall glass automobile headlamp. known as a Sealed Beam headlamp. A small electric furnace generally designated I0, com--` prising a platinum liner |I surrounded by. a

ceramic refractory shell I2, an electric resistance4 element I3 andan outer insulating refractory shell I4, is mounted on Va swinging support I5." The furnace I0 contains a molten supply of 'soft glass I6, preferably Vthe composition 1 described above. which issues as a continuous'stream I1' from anA orifice I8 in the bottom of the furnace I0. provided inthe rim of a lens or cover glass 20 for a Sealed Beam" headlamp which is preheated as mentioned above. 'The lens 20 is mounted on a support' 2| adapted to be horizontally rotated by Aa motor and reducing gear 22 throughs.

belt 23'.

AIn operation the furnace I0 is swung from an idlingv position (not shown) into the operating' position over the lens 20 so that the stream IT- falls into the groove I9 during one complete revolution of the support 2|, after which the fur- This sufiices to fill the groove I9 uniformly to a depth less than full andi nace I0 is swung aside.

leaves space for the exact registration therewith of a tongue on the rim of the reflector part of the headlamp (not shown) when the reflector is subsequently welded to the lens 20. Thus the invention may provide as an article of manufacture a glass part provided with an integral strip of a soft brazing glass ready for the subsequent joining thereto of another glass part by fusion welding without distortion of the parts.

Fig. 2 illustrates a nished headlamp of the- Sealed Beam type which comprises a lens 24 similar to the lens 20 of Fig. 1 and fusion welded to a glass reflector 25 by a thin layer 26 of soft glass, the reector being ment 21 and electrodes 28.

' In Fig. 3 is shown a cathode ray tube compris-v ing an accurately shaped face 29 joined to a conical body 30 by an integral layer 3| of soft glass.

a layer 34 of soft glass disposed between the face of the sheet 32 at its border and an upstanding rib of glass 35 with -which the sheet 33 is provided. In this case junction of the sheets 32 and 33 may be accomplished as shown in Fig. 6 wherein a rod of soft glass 36 is disposed on an upstanding rib 31 of a glass sheet 38 and another sheet of glass 39 is disposed on the glass rod 36. Welding may be accomplished by passing the assembled sheets of glass through a lehr having a maximum temperature above the softening temperature of the soft glass but below the deformation temperature of the glass sheets. Such a seal would be difficult or impossible to make by rI'he stream I1 falls within a.` groove I9.

provided with a fila# nated. 45, comprises yidentical upper yand lower halves-which are provided with rims l46 and projecting ribs 41, the rims and ribs of the twohalves wherein strips 49 of soft vglass are disposed b etween the respective rims '50 and ribs 5| of two glass parts similar to the two halves of the panel of Figyl. The opposing rims 50 land ribs 5l vof the two glass ,parts arebrought into contact with therespective intermediate strips 49 and the entn're .assemblyis heated to a temperaturesufcient to soften the strips 49 but insufficient to soften thetwo. glass parts after which the assembly is annealed. j The glass panel described in Figs. 9 and 10 is adapted to be converted into a panel type fluorescent lamp by applying Yto all interior surfaces a .coating of iiuorescent material and providing two inserted electrodes (not shown), the electric discharge being constrained by the intervening ribs to traverse the longest possible path between the `electrodes and consequently touniforrnly illuminate the entire panel.

In Fig. 12 a glass tube 52 isvprovided with a longitudinally disposed upstanding glass partition 53. `Rods 54 of soft glass are longitudinally positioned along the lower edge of the partition 53 in which conditionthe assembly is heated sufficiently to soften the rods 54 and cause the soit glass to flow and make a uniform joint between the wall of the tube 52 and the edgeof the partition 53. In a similar manner soft glass rods mayT be applied and fused into place at the opposite edge of the partition 53 whereupon a double bore tube is produced similar to that illustrated in Fig. 13 in which a glass tube 55 is provided with a glass partition E joined thereto through an integral joint 51 of soft glass.

The invention possesses numerous benets and advantages, l outstanding among which is the ability to form junctions of hard glasses at temperatures below their strain temperatures, the latter temperature being dened as that temperature at which four hours is required to annealthe glass (Littleton and Roberts, Jour. Am. Opt. Soc, vol. 4, p. 224, 1920, `above referred to). That is to say, glasses having expansion coefficients within the range. specied above and having straini temperatures above the softening temperature ofthe soft brazing glass of the invention can be joined by means of said soft brazing glass without introducing permanent strain in the composite article and yhence avoiding the necessity for yannealing the article after thejoint is complete. Since hard 'glasses of high expansion can be strengthened by tempering or chilling to purposely introduce permanent uniform stresses -n the glass, the new soit glasses of the invention can be employed to join such tempered glass parts Without releasing the stresses.

The new soft soldering glasses also may be advantageously used in the production of` glassto-metal seals in which aglass part having an expansion -coeicient in the range x10*7 to l00 107 per C. (0 to 300 C.) is joined to a metal part having a. similar expansion coefficient by Van intermediate layer of the new soft soldering g ass.

The new soit glasses described above and composite articles composed in part of such glasses, as also described above, are claimed in application Ser. No. 141,831, filed February 1, 1950, in tony name as a division of the instant applicaion.

I claim:

An electric lamp comprising a concave vitreous reiiector portion having an inner surface with a. reecting coating, a translucent vitreous cover portion hermetically sealed to the rim of said reflector portion and forming yan enclosure therewith, one of said portions having a groovereceving vitreous material having Aa softening point considerably lower than that of the parts sealed together, the other having a `boss received in said groove and embedded in said vitreous material of considerably'lower softening point.

ROBERI H. DALTON.

References Cited in the le of this patent UNITED STATES PATENTS Number Name Date 2,210,489 Lemmens et al. Aug. 6, 1940 2,240,352 Schmidt Apr. 29, 1941 2,393,448 Armistead Jan. 22, 1946 2,417,898 Armistead Mar. 25, 1947 2,464,990 Piagge .Mar. 22, 1949 

